Contact unit or assembly



June 15 1926.

H. FORD CONTACT UNIT OR ASSEMBLY Filed Dec. 19, 1919 -J lilllill N ryj'ord W G Patented June 15, 1926.

OFFICE.

HENRY'FOBD, OF DEABBORN, MICHIGAN.

CONTACT UNIT OR ASSEMBLY.

Application filed December 19, 19.19. Serial N0. 346,154.

This invention relates to improvements in contact units or assemblies, pertaining more particularly to structures adapted to be bodily removed and inserted at will. I

The unit herein disclosed is adapted for use under various conditions of service, but for the purpose of description I have shown it as-employed as the primary contact member in connection with the general magneto 10 system of :a motor vehicle, the particular showing being that of a well known type of structure wherein the magnet structure is bodily rotatable by the operation of the motor, the coils which cooperate with the magnet being carried by a stationary .ele- .ment, the circuit arrangements being such as to bring the current to asuitable contact .mem'ber carried by the coil support from where it is connected up to the various electrical circuits, ignition and otherwise; by

the use of a coil unit carried by the casing of the motor, the unit having provision to attach a lead and have a contact point or surface which is adapted .to make contact with such supportcl.rricd contact when the unit is properly seated in its particular support.

This particular form of use of the "unit presents certain problems, such, for 'instance, as the etfects 'of vibrations from motor operation, jars :and shocks provided by travel under service conditions, the. pos sibility of variations in spacing between the coil support and the of the motor which carries the unit, etc. These condi- "tions tend to limit the character of contact which can be employed, since, as .a general rule, the opposite side of the circuit is generally grounded on the frame of the vehicle. In practice, it is-found that the conditions are such as to require replacement of a contact at intervals in order that the circuits maybe properly maintained, especially the ignition circuits upon which the operation of the motor depends.

The present invention is designed not only to meet these conditions of'service in a way to :render the unit'of greater service ability but also has for its object the ability to produce a unit of this type with a decreased number of parts, readily manufactured and assembled, and in which the manufacture and assembly is of a type which will pro vide a general decrease in the cost of production, the simplicity of construction 'of the unit being of particular advantage where quantity production is desired, the

decreased cost .of manufacture permitting the unit to be produced and sold at a smaller cost to the user.

Tothese and other ends, the nature of which will be readily understood as the invention is hereinafter disclosed, said invention consists in the improved construction and combination of parts hereinafter more fully. described, illustrated in the accompanying drawings, and more particularly pointed out in the appended claims.

In the accompanying drawings, in which. similar reference characters indicate similar parts .in each of the views,

Figure 1 is a longitudinal sectional view through one embodiment of a unit construction in accordance with the general principles of thepresent invention.

. Fig. 2 is an end view of. the unit.

Fig. 3 is aview partly in section and partly in elevation of. a portion of a magnetosystem-such as that described, the view showing a unit in operative position.

Fig. 4 is a sectional. view taken on the line IV-IV of Fig. 1.

*Figpf) is a fragmentary detail showing a portion of the unit securing member.

In the drawings' 0; indicates the casing which .incloses the motor, the latter -carry ing a fly wheel 7) to which are secured a plurality of magnets '0, the rotation of the motor carrying these magnets in a circular path opposite the ends ofa plurality of coils d mounted on a stationary coilsupport e, the coils being-connected together H1 such manner as to lead the current therefrom to contact member f having a face supported on the opposite side 'of support e and opposite a threaded opening c in casing a, tliis openi ng being adapted to receive the primary contact, the latter carrying the specificcontact adapted to maintain contactengagement with contact member 'f,

quantity basis :and therefore maintain the- 7 cost of production as low as possible under such conditions.

It is to. a unit or assembly for meeting conditions of this severity that the present invention pertains, the arrangement of the invention producing a more efficient result with a considerable decrease in number of parts and permitting of production under quantity conditions. A unit of this type is shown in position in Fig. 3, and the detail construction of it. now to be described, is shown in the remaining figures.

1O designates the unit securing member, 11 the terminal member, 12 an insulating bushing, and 13 the contact employed. These are so formed and assembled as to provide a unitary structure in which the parts are so arranged as to prevent any possibility of short circuiting through engagement of the contact or terminal with the supporting case or unit supporting member, and atthe same time provide a unit in which the contact element is of a form to constantly maintain the contact engagement with contact member f regardless of vibrations, jars, etc.

Member 10 is shown as having a bore of suitable diameter, the exterior of the member having a threaded portion 10 and an enlarged portion 10 the latter preferably having a c'onfiguraton which will permit of ready manipulation for the insertion or removal of the assembly from the opening a, one form of this portion or head 10 being indicated in the drawings as having the contour of a nut. The outer end of the borepreferably that portion located in the head 10 is preferably of increased diameter with the wall formation, in cross section, of suitable configuration which is adapted to retainthe bushing 12 against longitudinal and rotatable movement within the member. The particular configuration shown is that of a plurality offaces which extend angular to the axis of the member, thus producing an annular rib-like structure 10 and an annular depressed portion within which the bushing extends.

One or more of said faces are provided with depressions 10 into which the material of the bushing extends in the form of complementary projections, this complementary formation serving to revent rotative movements of the bushing. Obviously, the projection or depression configuration may be of any suitable design, and may be re versed from the particulararrangement disclosed, in that the projections may be carried by member 10 and the recesses by the bushing; the particular arrangement shown in the drawings is, however, preferred, since it permits of a more ready production of the bushing which is produced individually for each unit by molding or other suitable form or production. And it will be understood, of course, that the number of these complementary configurations may be varied, it being preferred to employ more than one, but, where conditions permit, it is possible to limit the number to one.

Terminal member 11 has one of its ends enlarged, as at 11 to provide a face 11 of greater area than that of a cross-section of the main portion of the member, the opposite end of the member being externally threaded, as at 11 to permit of the usual clamping action on the lead connections by the use of a nut 1% or other suitable formation. The outer end of member 1.1 is pref erably counter-sunk, as at 11, for a purpose presently described.

Member 12 is of insulating material and is preferably of a material which can be molded, example of which is the material known as bakelite, the bushing being molded with the internal face of member 10 and a portion of the external face of the member 11 forming walls which serve as mold walls during the molding operation. As will be understood, additional mold walls are provided to give the desired configuration to the bushing, a preferred configuration being that shown in Fig. 1 of the drawings, in. which the bushing extends beyond the opposite ends of member 10, whilethe opposite end faces of member 11 are both exposed with respect to the bushing.

As will be seen more particularly from Fig. 1, securing member 10 and terminal member 11 are positioned relatively to each other and to the insulatin'g element 12, that a plane which is normal to the axis of the unit and located at the exposed face 11- the inner end of the terminal member-is approximately on the outer plane of the securing member 10, thus practically placing the terminal member to one side of such plane and the securing member on the opposite side of the plane. As a result, there is no material portion of the length of the insulating member, intermediate itsjends, that is not supported by a metallic member, the metallic members thus forming a sup- 7 port for the insulating element or member to prevent its breakage because of non-support. In addition, however. this arrangement provides a material advantage in the molding of the material of the. element 12, in that the wall of the insulating element opposite that which is in contact with either member 10 or 11. can be provided by a removable die which forms no part of the unit assembly, the completed element 12 thus having this opposite face exposed, the face opposite the securing memberforming the wall of the well within which the maj or por tion of contact 13 is positioned, while the wall opposite the terminal member forms the outer exposed portion of the unit insulation above the securing member.

means In the particular embodiment shown, member 11 is positioned in axial alignment with the axis of member 10, and these memhere are relatively positioned so that portion 11" is approximately on the plane of the outer end of member 10, this relative position permitting the use of members of sufficient size and yet permit of the formation of a bushing which Will locate ex 1 portions of members 10 and 11 at su cient distances apart as to prevent liability of this distance being bridged electrically under service conditions, thus avoiding the possibility of short circuiting the magneto system. Face 11 is an exposed face provided by the formation in bushing 12 of an axial recess 12 which extends from the inner end of the bushing to the plane of such face, the bushing wall extending beyond the inner end of member 10 a sufficient distance to provide against the possibility of short circuiting between member 10 and contact 13.

Members 10, 11 and 12 are thus made a unitary structure of a strength which will meet all ordinary service conditions, inembers 10 and 11 being held from relative rotative movement with respect to bushing 12 through the configuration of the en la ed bore of member 10 heretofore described and by providing the body portion of member 11 with an external configuration which is non-ciicula-r in cross sectionthis configuration, in the drawings, being shown as angular, but which, obviously, may be of any preferred form.

Contact element- 13 is, itself, an individual element adapted to be secured into the unitary assembly of members 10, 11 and 12, after the latter has been completed, the contact element having an end portion or stem 13 which extends axially through an opening 11 of the member 11, the free end of stem 13* extending into the counter-sink 11, solder, indicated at 15, but placed within the counter-sink and serving to retain the Contact from being withdrawn from member 11.

The contact 13 is preferably formed of a length of wire or strip having resilient characteristics, the intermediate portion of the wire being arranged in the form of a coil of the general type shown in Fig. 1, in which, the convolutions are not of the same diameter throughout, aportion of the coil, indicated at 13' having its convolutions of a diameter approaching somewhat the diameter of recess 12", the outer convolution for this portion being preferably arranged to produce a convolution face which extends approximately on a plane intersecting the axis of the coil at right angles, this face being adapted, when the parts are assembled, to rest against face 11', the end of this convolution being bent into a position which will locate stem 13" substantially on the axis of the coil. The convolutions of portion 13" are preferably spaced material distances apart.

The opposite end of portion 13" of the coil is continued in the form of convolutions which decrease in diameter toward the 0pposite end of the length of wire, these convolutions forming a portion 13 which is more or less cone shaped, the convolutions of this portion being spaced less distances apart-the space preferably decreasing-and produces a portion which, by reason of its conformation, is less responsive to the resilieney than that of portion 13", the free end of portion 13 being brought into the axis of the coil and bent so as to rovide a projecting portion 13 exte ing in the direction of the axis and in approximate alignment with stem 13, portion 13" being a configuration to produce the point or surface which is to contact with contact member As will be understood, element 13 is thus of a form capable of yielding when the unit is placed in position, thus placing the coil under tension exerted toward the face of contact member f. And this tension is eifeo five to maintain the contact engagement regardless of vibration eflects, jars, etc, which occur under service conditions And as will be understood, the yielding action is confined mainly to that portion of the coil which is Within recess 12, so that the coil is free to accommodate itself during the placing of it under tension or compression without liability of bringing the coil into a position Where it may set up a short circuiting action, the relative stiffness of portion 13 preventing the exposed end of the coil from pro ducing this efiect.

As will be understood, the contact unit is practically formed of the four elements 10, 11, 12, and 13, elements 10, 11 and 13 being of a configuration readily manufactured and capable of production under high capacity conditions, members 10 and 11 having con figurations which enable the product-ion of bushing 12 in a simple and efficient manner, the unitary assembly thus produced being of a form in which it is necessary only to insert stem 13 in the terminal member 11 and solder the end of the stem in position, thus completing the unit.

The arrangement is such as to provide for durability and eflicient service, and capable of production at comparatively low costs and on a quantity production basis.

\Vhile I have herein shown and described a preferred embodiment of the invention, it will be readily understood that changes and modifications therein may be found desirable or necessary in meeting the various exigencies of use and service, and I desire to be understood as reserving the right to make any and all such changes or modificallu tions as may be found desirable or essential in so far as the same may tall within the spirit and scope of. the invention as expressed in the accompanying claims, when broadly construed.

Having thus described my invention, what I claim as new is:

,1. A contact unit comprising an outer member adapted to be secured in a contact support, a terminal member axially alined therewith, said members being relatively positioned by a unitary insulating element with which both members are permanently and directly connected and in anchored and insulated relation to each other, and a con tact member raving one end secured to the terminal member and its opposite end projecting beyond the element, said contact member being yieldable in the direction of axis oi the unit, the arrangement of the outer end terminal members relative to each other and to the insulating element being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane of the outer end of the outer member, whereby the wall oi the insulating element opposite the wall which is in contact with either of said members presents an exposed surface of the insulating element.

2.' A. contact unit comprising an outer member adapted to be secured in contact support, a terminal member axially alined tl'ierewith, said members being relatively positioned by a unitary insulating element with which both members are permanently and directly connected and in anchored and insulated relation to each other, said element having an axial recess leading from its inner end, and a contact member extending freely through said recess and having one end socured to the terminal member and its opposite end projecting beyond the recessed end of the element, the arrangement of the outer end terminal members relative to each other and to the insulating element being such that plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane of the outer end of the outer member, whereby the wall of the insulating element opposite the wall wnich is in contact with either of said members presents an exposed surface of the insnlatin element.

3. As a means for permanently connecting the terminal-member of a contact unit with a unit securing member and wherein the.

members are permanently positioned relatively to and insulated from each other in a manner to render the securing member inactive as a part of the current flow-path of the unit, a bushing of insulating material molded to traverse the interior or" and project beyond the opposite ends of the securing member andto locate the terminal member on the axis of the unit with the opposite ends of the terminal member exposed, the arrangement of the unit-securing member andvthe terminal member relative to each other and to the bushing being such that a plane normal to the axis of the'unit at the inner end of the terminal member extends on approximately the plane of the outer end of the unit-securing member, whereby the wall of the lnlshing opposite the wall which in contact with either of said members presents an exposed surface oi' the insulating element.

4. As a means for permanently connecting the terminal member a contact unit with a unit securing member and wherein the members are permanently positioned relatively to and insulated from each other in a manner to render the securing member inactive as a part of the current flow'path of the unit, a bushing of insulating material molded to traverse the interior of and projcct beyond the opposite ends of the securing member and to locate the terminal member on the axis of the unit with the opposite ends of the terminal member exposed, eachmemher having configuration to produce interengagement with the molded material to pre vent relative rotative movement between the members, the arrangement of the unitsecuring member and the terminal member relative to each other and to the bushing being such that plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane of the outer end of the unitsecuring member, whereby the wall of the bushing opposite the wall which is in contact with either of said members presents an exposed surface of the insulating ele ment.

5. As a means for permanently connecting he terminal and unit'securing members of a contact unit with the members in insulated relation and with the members relatively positioned to render the securing member inactive as a part of the current flowpath of the unit, a bushing of insulating material molded to traverse the interiorof and project beyond the opposite ends of the securing member and to locate the terminal member on the axis of theunit with its opposite ends exposed, said members having faces sel of the bushing, the securing member having the outer end ofits bore of increased diameter with walls of the enlarged portion of the bore extending angular to the axis of the member to form annularly extending ribs adapted to anchor the bushing, the arrangement of the terminal and unit securing members relative to each other and to the bushing being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on aping to control the molding proximately the plane of the outer end of the unit-securing member, whereby the wall of the bushing opposite the wall which is in contact with either of said members presents an exposed surface of the bushing. 6. As a means for permanently connecting the terminal and unit-securing members of a contact unit with the members in insulated relation and with the members relatively positioned to render the securing member inactive as a part of the current flow-path of the unit, a bushing of insulating material molded to traverse the interior of and project beyond the opposite ends of the securing member and to locate the terminal men'rber on the axis of the unit with its opposite ends exposed, said members having faces serving to control the molding of the bushing, the securing member having the outer end of its bore of increased diameter with walls of the enlarged portion of the bore extending angular to the axis of the member to form annularly extending ribs adapted to anchor the bushing, said angular wall formation having at least one depression active in the formation of a complemental projection formation of the bushing, said projection and depression formations cooperating to prevent relative rotative movements of the member and bushing, the arrangement of the terminal and unit-securing members relative to each other and to the bushing being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane ofthe outer end of the unit-securing member, whereby the wall of the bushing opposite the wall which is in contact with either of said members presents an exposed surface of the bushing.

7 As a means for permanently connecting the terminal and unit-securing members of a contact unit with the members in insulated relation and with the members relatively positioned to render the securing member inactive as a part of the current flow-path of the unit, a bushing of insulating material molded to traverse the interior of and project beyond the opposite ends of the securing member and to locate the terminal member on the axis of the unit with its opposite ends exposed, said members having faces serving to control the molding of the bushing, the securing member having the outer end of its bore of increased diameter with walls of the enlarged portion of the bore extending angular to the axis of the member to form annularly extending ribs adapted to anchor the bushing, said angular wall formation and molded bushing having complemental projection and depression configurations operative to prevent relative rot-ative movement of the member and bushing, the arrangement of the terminal and unit-securing members relative to each other and to the bushing being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on up proximately the plane of the outer end of the unit-securing member, whereby the wall of the bushing opposite the wall which is in contact with either of said members presents an exposed surface of the bushing.

8. As a means for permanently connecting the terminal and unit-securing members of a contact unit with the members in insulated relation, and with the members relatively positioned to render the securing member inactive as a part of the current flow-path of the unit, a bushing of insulatin n'iaterial molded to traverse the interior 0 and project beyond the opposite ends of the securing member and to locate the terminal member on the axis of the unit with it-sopposite ends exposed, said members having faces serving to control the molding of the bushing, the securing member having the outer end of its bore of increased diameter with walls of the latter portion extending angular to the axis of the member to form annularly extendin ribs adapted to anchor the bushing, said terminal member having a non-circular configuration in cross-section, the arrangement of the terminal and unit-securing members relative to each other and to the bushing being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane of the outer end of the unit-securing member, whereby the wall of the bushing opposite the wall which is in contact with either of said members presents an exposed surface of the bushing.

9. In contact unit structures wherein the terminal member is carried in anchored insulated relation to the unit securing member, a terminal member having means whereby a conductor may be detachably connected thereto, said means being permanently exposed relative to the insulation, said terminal member having a permanently anchored relation to the insulation and having an end formation to provide a face of increased area exposed within the insulation and also having an opening extending from end to end of the member, and a contact element having one end extending into and anchored relative to said opening and having its opposite end projecting beyond the insulation to form a contact surface 6? point characteristic, said element having an intermediate portion in contact with said face, the arrangement of the terminal and unitsecuring members relative to each other and the insulation which supports them in anchored relation to each other being such that a plane normal to the axis of the unitat the inner end of the terminal member extends on approximately the plane of the outer end of the unit-securing member,

whereby the wall of the insulation opposite the Wall which is in contact with either of said members presents an exposed surface of the insulation.

10. In contact unit structures wherein the terminal member is carried in anchored insulated relation to the unit-securing n1e1nber, a. terminal member having means whereby a conductor may be detachably connected thereto said means being per manentiy exposed relative to the insulation, said terminal member having a permanently-anchored relation to the insulation and having an end formation to provide a face of increased area exposed within the insulation and also having an opening extending from end to end of the member, and a contact element having'one end extending into and anchored relative to said opening and having its opposite end projecting beyond the insulation, to form a contact surface of point characteristic, said element having an intermediate portion in contact with said face, the portion of said element intermediate said face and the contact surface being of coil formation, the arrangement of the terminal and unit-securing members relative to each other and the insulation which supports them in anchored relation to each other being such that a plane normal to the axis of the unit at the inner end of the terminal member extends on approximately the plane of the outer end of the unit-securing member, whereby the wall of the insulation opposite the wall which is in contact with either of said members presents an exposed surface of the insulation.

In testimony whereof I afiix my signature.

HENRY FORD. 

